Seal Cup and Mounting Caps for Toilet Installation

ABSTRACT

A unique seal cap is used for pressure testing waste and drain pipes prior to the wax free installation of a toilet. The disclosed seal cap artfully fits over a toilet flange without interfering with the subsequent configuration and wax free installation of a toilet. The seal cup system also stores new caps that are uniquely threaded to avoid dangerous and unsightly screws or protruding traditional screw caps. The disclosed screw cap systems provide a first or inner cap having centrally disposed inner threads to secure a toilet to a flange. The first or inner caps also have outwardly facing threads at the outer circumference, enabling the attachment of outer caps that are more bulbous than the caps of the prior art, with the disclosed outer caps being safer, having a less pointed protrusion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This utility application claims the benefit of and priority date of U.S. application 62/821,040 filed on Mar. 20, 2019, the contents of which are incorporated herein by reference.

COPYRIGHT AND TRADEMARK NOTICE

This application includes material which is subject or may be subject to copyright and/or trademark protection. The copyright and trademark owner(s) has no objection to the facsimile reproduction by any of the patent disclosure, as it appears in the Patent and Trademark Office files or records, but otherwise reserves all copyright and trademark rights whatsoever.

BACKGROUND OF THE INVENTION (1) Field of the Invention

The invention generally relates to plumbing installation systems. More particularly, the invention relates to means and methods of testing a toilet waste and drain systems, storage of fasteners, new fasteners and wax free toilet installation.

(2) Description of the Related Art

The known related art fails to anticipate or disclose the principles of the present invention.

In the related art, general wax free toilet installation systems are known. For example, wax free systems by Scott Duncan include U.S. Pat. No. 9,512,605—Wax free systems with springs for new and existing toilets—U.S. Pat. No. 9,663,934—Floating Nipple Assemblies for Wax Free Installation of New and Existing Toilets and U.S. Pat. No. 9,062,445—Wax Free Kit for New and Existing Construction. These products are innovative and commercially successful. But, the prior art fails to disclose, suggest or anticipate efficient means of testing waste and drain pipe and fastening wax free systems in a manner integral with the wax free installation systems, thus, there is a need in the art for the disclosed embodiments.

BRIEF SUMMARY OF THE INVENTION

The present invention overcomes shortfalls in the related art by presenting an unobvious and unique combination and configuration of methods and components to provide a seal cap used for testing waste and drain pipes prior to the wax free installation of a toilet. The disclosed seal cap artfully fits over a toilet flange without interfering with the subsequent configuration and wax free installation of a toilet. The disclosed seal cup system also stores new caps that are uniquely threaded to avoid dangerous and unsightly screws or protruding traditional screw caps. The disclosed screw cap systems provide a first or inner cap having centrally disposed inner threads to secure a toilet to a flange. The first or inner caps also have outwardly facing threads at the outer circumference, enabling the attachment of outer caps that are more bulbous than the caps of the prior art, with the disclosed outer caps being safer, have a less pointed protrusion.

Disclosed embodiments include clever caps or caps with thermally applied inserts that overcome shortfalls in the related art by providing an economic lower threaded portion in the cap and providing an upper void, allowing for bolts or studs to be used in an uncut condition.

These and other objects and advantages will be made apparent when considering the following detailed specification when taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 exploded view of disclosed components

FIG. 2 compact view of disclosed components in market condition or configured for packaging

FIG. 3 separate components of the prior art

FIG. 4 perspective view of test seal in place

FIG. 5 perspective view of components and toilet aligned for installation

FIG. 6 perspective view of components and toilet fastened together

FIG. 7 perspective view of inner nut installed and outer cap in background

FIG. 8 perspective view of inner nut and outer cap secured to installation bolt and closet flange

FIG. 9 depicts top perspective view of a clever cap or thermal cap

FIG. 10 depicts a bottom perspective view of a clever cap or thermal cap

FIG. 11 depicts a clever cap or thermal cap and an insertion piece

FIG. 12 depicts a sectional view of a clever cap or thermal cap

REFERENCE NUMERALS IN THE DRAWINGS

100 seal cup

110 lower cavity of seal cup 100

130 upper lip of seal cup 100

140 feet of seal cup 100

200 cap assembly

220 inner cap of cap assembly 200

230 outer threads of inner cap 220

260 outer cap of cap assembly 200

270 inner threads of outer cap 260

300 attachment bolts

400 wax free spring seal

500 closet flange

520 bolt voids defined within closet flange 500

600 toilet

620 toilet horn

700 prior art

800 thermal cap

810 outer curved surface of thermal cap 800

815 bottom surface of thermal cap 800

820 outer flat surface of thermal cap 800

830 lateral support structure between outer cap surface and cap sleeve 840

840 cap sleeve, sometimes found in the center portion of a thermal cap 800

850 superior void of cap sleeve, defined by the inner walls of the cap sleeve and inner wall of the thermal cap

900 threaded insert

910 outer friction ridges

920 inner threads

930 cylinder

940 exterior lip

950 superior smooth section

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The following detailed description is directed to certain specific embodiments of the invention. However, the invention can be embodied in a multitude of different ways as defined and covered by the claims and their equivalents. In this description, reference is made to the drawings wherein like parts are designated with like numerals throughout.

Unless otherwise noted in this specification or in the claims, all of the terms used in the specification and the claims will have the meanings normally ascribed to these terms by workers in the art.

Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising” and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in a sense of “including, but not limited to.” Words using the singular or plural number also include the plural or singular number, respectively. Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application.

The above detailed description of embodiments of the invention is not intended to be exhaustive or to limit the invention to the precise form disclosed above. While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. For example, while steps are presented in a given order, alternative embodiments may perform routines having steps in a different order. The teachings of the invention provided herein can be applied to other systems, not only the systems described herein. The various embodiments described herein can be combined to provide further embodiments. These and other changes can be made to the invention in light of the detailed description.

Any and all the above references and U.S. patents and applications are incorporated herein by reference. Aspects of the invention can be modified, if necessary, to employ the systems, functions and concepts of the various patents and applications described above to provide yet further embodiments of the invention.

FIG. 1 depicts an exploded view of disclosed components that may take kit form and may include a seal cup 100 with the seal cup comprising a lower cavity 110, an upper lip 130 and a plurality of feet 140 attached to a lower surface of the upper lip. The feet 140 of the seal cup may mate into or fit into bolt voids 520 with the bolt voids defined within a closet flange 500. When the feet 140 of the seal cup are inserted into the voids of the closet flange, a pressure test may be performed to test the integrity of the related waste and drain system. This pre-installation test is typical in modern day construction practices. Moreover, a lower portion of the upper lip may have concentric walls to comport with and seal with an upwardly urged top seal, with the top seal sometimes urged upwardly by use of a threads or springs or other means. Moreover, a rib seal system may be employed to seal a seal cup to the closet flange. Sometimes the downward force of attachment of a cup seal may be used to seal with a closet flange.

For toilet installation, attachment bolts 300 may be fitted into the bolt voids of the closet flange to secure a wax free spring seal 400 or analogous sealing component between the closet flange and toilet. The attachment bolts will protrude past the toilet and be secured by the cap assembly 200. The cap assembly may comprise an inner cap 220 with the inner cap comprising inner threads to comport with the attachment bolts and outer threads 230 to mate with the inner threads 270 of the outer cap 260. The disclosed cap assembly system provides advantages over the prior art in that the inner cap 200 is made of a flexible material and takes on a wide profile so as to not crack or otherwise damage the toilet that is held in tension by the inner cap. The outer cap 260 provides advantages over the prior art in that the inner cap and attachment bolt are well covered in a wide profile such that children will not hurt themselves on the inner cap and will not easily remove the outer cap.

As shown and discussed further below, the seal cup 100 provides multiple uses in a compact form factor. The seal cup provides convenient means of sealing the closet flange for pressure testing and provides means of packaging, marketing and storing related components such as the cap assembly components and attachment bolts. For further all in one packaging, the seal cup may fit into a wax free spring seal 400 and a closet flange may fit over the wax free spring seal. Thus a plumber or DIY homeowner may conveniently purchase all parts needed to effortlessly and quickly set a toilet.

FIG. 2 depicts a kit ready for sale or marketing. Not shown is a clear plastic seal that may be used to contain the contents of the seal cup 100. A disclosed kit may contain or include a seal cup filled with attachment bolts, two inner caps and two outer caps. A wax free spring seal or similar seal system may hold the seal cup. A closet flange may be disposed around the wax free spring seal.

FIG. 3 depicts the current state of disorganization and potential for mismatched parts of the prior art. In the prior art, toilet components are sold separately and often in different areas of a home improvement store. The shown pressure test cap has no use in storing components. The wax ring is now obsolete by use of a wax free spring seal or similar system. The bolt caps of the prior art often fail to total enclose attachment bolts and sometimes leave the ends of the attachment bolts exposed. The caps of the prior art are often a choking hazard as young children may remove the caps and swallow them.

FIG. 4 depicts the disclosed seal cup 100 used as a test seal such that the waste and drain lines may be pressure tested prior to installation of the toilet. The feet 140 of the seal cup 100 provide a toolless solution to pressure testing while providing convenient means of storing hardware needed after the pressure test. The lower cavity of the seal cup is well positioned to store the cap and bolt components such that they are unlikely to be lost during the construction process.

FIG. 5 depicts the beginning of the toilet installation process wherein the attachment bolts 300 are secured into the voids 520 of the closet flange 500. The wax free spring seal 400 is centrally disposed within the closet flange. The horn 620 of the toilet 600 may be disposed within the top portion of the wax free spring seal 400. The upper or superior ends of the attachment bolts 300 may be inserted through voids of the toilet as shown in FIG. 6.

FIG. 6 depicts a further progression of toilet installation wherein the horn of the toilet has been inserted into the top void of the wax free spring seal.

FIG. 7 depicts an attachment bolt 300 passed through the toilet and now secured to the toilet by use of an inner cap 220. The inner cap may comprise outer threads 230 used to secure the outer cap 260 by use on the inner threads 270 of the outer cap.

FIG. 8 shows a finished or near finished assembly of a toilet using the disclosed components and methods.

FIG. 9 depicts a thermal cap 800, with the thermal cap comprising one or more outer flat surfaces 820 and one or more outer curved surfaces 810. The combination of the flat and curved surfaces provide an advantage of allowing the cap to be turned by hand.

FIG. 10 depicts a bottom perspective view of a thermal cap 800. A threaded insert 900 is shown as disposed within a cap sleeve 840 of the thermal cap. A threaded insert may be heated and then inserted into a cap sleeve, with the heat of the threaded insert causing material of the cap sleeve to melt or deform. Upon cooling, the threaded insert may be rigidly or securely disposed within the cap sleeve or thermal cap.

A thermal cap may comprise a plurality of lateral support structures 830, that provide an advantage over the prior art in allowing air gaps between the exterior walls of the thermal cap and the cap sleeve. The air caps reduce weight and the cost and materials used in constructing the thermal cap.

FIG. 11 depicts a thermal cap having a bottom surface 815 and a cap sleeve 840 with the thermal cap ready to accept a heated threaded insert 900. A threaded insert may comprise a general cylinder body having an exterior surface comprising one or more rings of outer friction ridges 910. The outer friction ridges overcome shortfalls in the prior art by sometimes melting into a cap sleeve and thus quickly and securing attaching with in the cap sleeve. A threaded insert may comprise interior threads, that may comport with attachment bolts or other fasteners.

A threaded insert 900 may comprise an exterior lip 940 with the exterior lip providing advantages over the prior art as being a continuous anchor point that may be embedded into the cap sleeve or thermal cap. A threaded insert may comprise a smooth section 950 that may be above or superior to the exterior lip. The smooth section or superior smooth section overcomes shortfalls in the art by providing a contrast or different elevation from the exterior lip, to help the exterior lip not set too deeply into the thermal cap.

FIG. 12 depicts a superior or upper void 950 of the cap sleeve 840. The upper void provides advantages over the prior art by allowing fasteners such as attachment bolts to be untrimmed or uncut as excess fastener length may be disposed within the upper void 950.

The disclosed embodiments may include the following items:

A toilet installation and pressure testing kit, the kit comprising:

a seal cup (100) with the seal cup comprising a lower cavity (110), an upper lip (130) and a plurality of feet (140) with the plurality of feet attached to a lower surface of the upper lip.

The seal cup of item 1 wherein the lower surface of the upper lip comprises a concentric wall that comports with a wax free spring seal (400).

The seal cup of item 1 wherein the upper lip comprises a planar surface, not defining a lower cavity.

The kit of item 1 further comprising a plurality of attachment bolts (300);

The kit of item 4 further comprising a plurality of cap assemblies (200), with each cap assembly comprising:

an outer cap (260) with the outer cap having an inside surface comprising inner threads (270);

an inner cap (220) with the inner cap comprising outwardly disposed outer threads (230).

The kit of item 5 further comprising a wax free spring seal.

The seal cup of item 1 further comprising a transparent member covering a top void of the seal cup.

The seal cup of item 1 further comprising a plurality of thermal caps (800) with each thermal cap comprising an outer curved surface (810), an outer flat surface (820), a bottom surface (815) and a cap sleeve (840).

The seal cup further comprising a threaded insert disposed within the cap sleeve. 

What is claimed is:
 1. A toilet installation and pressure testing kit, the kit comprising: a) a seal cup (100) with the seal cup comprising a lower cavity (110), an upper lip (130) and a plurality of feet (140) with the plurality of feet attached to a lower surface of the upper lip.
 2. The seal cup of claim 1 wherein the lower surface of the upper lip comprises a concentric wall that comports with a wax free spring seal (400).
 3. The seal cup of claim 1 wherein the upper lip comprises a planar surface, not defining a lower cavity.
 4. The kit of claim 1 further comprising a plurality of attachment bolts (300);
 5. The kit of claim 4 further comprising a plurality of cap assemblies (200), with each cap assembly comprising: i. an outer cap (260) with the outer cap having an inside surface comprising inner threads (270); ii. an inner cap (220) with the inner cap comprising outwardly disposed outer threads (230).
 6. The kit of claim 5 further comprising a wax free spring seal.
 7. The seal cup of claim 1 further comprising a transparent member covering a top void of the seal cup.
 8. The kit of claim 1 further comprising a plurality of thermal caps (800) with each thermal cap comprising an outer curved surface (810), an outer flat surface (820), a bottom surface (815) and a cap sleeve (840).
 9. The kit of claim 8 further comprising a threaded insert (900).
 10. The kit of claim 9 wherein the threaded insert comprises outer friction ridges (910), an exterior lip (840), a superior smooth section (950) and interior threads (920). 